EP0644207B2 - Polymère superabsorbant de pouvoir absorbant perfectionné et d'absorption sous pression améliorée - Google Patents

Polymère superabsorbant de pouvoir absorbant perfectionné et d'absorption sous pression améliorée Download PDF

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Publication number
EP0644207B2
EP0644207B2 EP94114621A EP94114621A EP0644207B2 EP 0644207 B2 EP0644207 B2 EP 0644207B2 EP 94114621 A EP94114621 A EP 94114621A EP 94114621 A EP94114621 A EP 94114621A EP 0644207 B2 EP0644207 B2 EP 0644207B2
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Prior art keywords
polymer
acid
blowing agent
monomer solution
superabsorbent polymer
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German (de)
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EP0644207B1 (fr
EP0644207A1 (fr
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Scott J. Smith
Eric J. Lind
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Stockhausen Louisiana Ltd
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Stockhausen Louisiana Ltd
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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15203—Properties of the article, e.g. stiffness or absorbency
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/42—Use of materials characterised by their function or physical properties
    • A61L15/60—Liquid-swellable gel-forming materials, e.g. super-absorbents
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F2013/530481—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials
    • A61F2013/530583—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials characterized by the form
    • A61F2013/530649—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials characterized by the form in sponge or foam
    • A61F2013/530656—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials characterized by the form in sponge or foam being cut into pieces

Definitions

  • the present invention relates generally to superabsorbent polymers exhibiting improved absorption under pressure and fast absorption rates. This invention particularly relates to providing a surface crosslinked superabsorbent polymer which incorporates a blowing agent.
  • Superabsorbent polymers are water insoluble, hydrogel-forming polymers capable of absorbing large quantities of aqueous fluids including synthetic urine, brines, and biological fluids such as urine, sweat, and blood, while retaining the absorbed fluids under pressure.
  • Hydrogel-forming superabsorbent polymers are useful as absorbents for water and aqueous body fluids when the polymers are incorporated in absorbent articles, such as disposable diapers, adult incontinence pads, sanitary napkins, and bandages.
  • Many of the existing superabsorbents are formed from unsaturated carboxylic acid monomers including acrylic acid, methacrylic acid, alkylacrylates, and acrylamides which are rendered water insoluble by crosslinking.
  • the degree of crosslinking affects the absorbent capacity and gel strength of a superabsorbent. Capacity is a measure of the amount of fluid which a given amount of superabsorbent polymer will absorb. Gel strength indicates the tendency of the hydrogel once formed to deform under an applied stress. Polymers exhibiting inadequate gel strength will form a hydrogel which deforms and fills the void space in an absorbent article, inhibiting absorbent capacity and fluid distribution throughout the article. Polymers having low absorbent capacity are incapable of absorbing a sufficient amount of the fluid encountered in use of a diaper or other absorbent article. A polymer having a high gel strength generally possesses a low absorption capacity, and a polymer having a high absorption capacity typically possesses a low absorption rate because of gel blocking phenomenon or low gel strength after absorption.
  • a superabsorbent polymer must possess is an acceptable level of extractable, water soluble polymer remaining within the superabsorbent.
  • the extractable polymer can leach out of a hydrogel when fluids contact the superabsorbent.
  • the extractables that leach out of the superabsorbent apparently lower the absorption speed and capacity of the superabsorbent, resulting in leakage of the fluid from an absorbent article.
  • superabsorbents generally possess sufficient capacity, but do not have adequate gel strength, swell rate (i.e., absorption speed) and absorption under pressure for the absorbent articles of reduced size and thickness that are now being produced.
  • swell rate i.e., absorption speed
  • absorption under pressure for the absorbent articles of reduced size and thickness that are now being produced.
  • the polymer has to perform the functions of the fluff fiber.
  • the polymer must quickly absorb fluid and transport it throughout an absorbent article without releasing the stored fluid from the swelled hydrogel on exertion of pressure. Accordingly, the swollen gel particles cannot impede absorption of additional fluid by forming a barrier, but must maintain their liquid permeability.
  • blowing agents have been incorporated into superabsorbents as described in U.S. -A- 5,118,719 and 5,145,713. As the blowing agent is dispersed throughout the monomer solution during polymerization, it releases carbon dioxide when heated. The porosity of the resultant superabsorbent polymer provides more surface area within the polymer particles, increasing the rate at which fluid is absorbed by the polymer.
  • the absorption under pressure of a superabsorbent has been improved by crosslinking the molecular chains at the surface of the polymer.
  • Surface crosslinkage also improves the gel strength of the polymer and reduces the amount of extractables at the polymer surface. Although capacity is reduced at the polymer surface, the core of the polymer, which has lower crosslink density, retains its absorbance capacity.
  • Crosslinking at the surface of the polymer particles provides spacings between the particles when swelled, allowing fluid to pass the swelled particles and travel throughout the absorbent article.
  • Surface crosslinkage frequently reduces the absorption speed of the polymer. While these materials possess adequate absorption under pressure, they absorb significantly slower than the fluff fiber they are replacing in thinner personal care articles.
  • the polymers which have been crosslinked at their surface are not porous materials like those disclosed in U.S. -A-5,118,719 and 5,145,713. Accordingly, these superabsorbents generally exhibit slow rates of absorption.
  • U.S. -A-4,666,983 and 5,140,076 disclose absorbent polymers formed from reacting an absorbent resin powder having a carboxyl group with a crosslinking agent having at least two functional groups per molecule to crosslink the surface of the polymer.
  • DE-B-4,020,780 describes surface crosslinked superabsorbent particles formed by coating monomers having acid groups with an alkylene carbonate.
  • -A-5,229,466 discloses surface crosslinking by treating a water swellable carboxyl group containing polymer with a solution of an N-(hydroxyalkyl)-beta-(meth)-alanine ester or a polycondensation product thereof.
  • a superabsorbent polymer made from acrylic acid, a water soluble polysaccharide and a crosslinking monomer having at least two polymerizable ethylenically unsaturated double bonds per molecule is described in U.S. -A-5,145,906.
  • Water absorbent resins surface treated with a polyquaternary amine are disclosed in U.S.-A-4,824,901.
  • one aspect of the present invention provides a superabsorbent polymer preparable by the process of first providing a solution containing carboxylic acid monomers or water soluble salts thereof, and a crosslinking agent, herein referred to as the monomer solution.
  • a carbonate blowing agent and a polymerization initiator are added, individually or in combination, to the monomer solution to form a carbonated monomer solution.
  • the carbonated monomer solution is then polymerized at temperatures ranging from about 0°C to about 130°C, forming a microcellular hydrogel.
  • the microcellular hydrogel is chopped or ground into gel pieces having a particle diameter ranging from about 0.1 mm to about 5.0 cm.
  • the gel pieces are dried at temperatures ranging from about 85°C to about 210°C, and are then ground to form a polymer having a particle size of from about 0.05 mm to about 5.0 mm.
  • a mixture is formed from 100 parts by weight of the polymer and about 0.001 to about 30 parts by weight of organic carbonates, polyquaternary amines or polyvalent metal compounds.
  • the polymer is reacted with the organic carbonates, polyquaternary amines or polyvalent metal compounds to crosslink molecular chains existing on a surface of the polymer, forming the superabsorbent polymer.
  • Another embodiment of the present invention is a method of making a superabsorbent polymer having improved absorption under pressure and absorption rate when absorbing aqueous body fluids by the above identified process.
  • a third embodiment of the invention is a method of improving the absorption under pressure and absorption rate of a superabsorbent polymer.
  • the superabsorbent polymer is made by the method as described above, and is then exposed to aqueous body fluids, when the superabsorbent polymer is under the exertion of pressure.
  • the superabsorbent polymer can be contained within a diaper, an incontinence pad, a sanitary napkin or a bandage.
  • An associated object of the invention is to provide a superabsorbent polymer having a core with a lower crosslink density as compared to the surface of the polymer such that the core retains its absorbance capacity.
  • Another object of the invention is to provide a superabsorbent polymer in which spacings exist between the polymer particles when swelled, allowing fluid to pass the swelled particles and travel throughout the absorbent article.
  • Yet another object of the invention is to provide superabsorbent polymer particles with better bulk, inter- and intra-particle permeability.
  • the present invention provides a hydrogel-forming superabsorbent polymer which can be incorporated in absorbent articles such as diapers, adult incontinence pads, sanitary napkins, and bandages.
  • the polymer can be used to effectively replace fluff fiber within these products because the polymer quickly absorbs fluid and transports it throughout the product without releasing the stored fluid from the swelled hydrogel on exertion of pressure.
  • the swollen gel particles do not impede absorption of additional fluid by forming a barrier, but maintain their liquid permeability.
  • the superabsorbent polymer of the present invention may be prepared by first forming a monomer solution containing carboxylic acid monomers or water soluble salts thereof, and an effective water insolubilizing amount of a crosslinking agent. A carbonate blowing agent and a polymerization initiator are added, individually or in combination, to the monomer solution to form a carbonated monomer solution. The carbonated monomer solution is then polymerized to form a microcellular hydrogel. The microcellular hydrogel is chopped or ground into gel pieces which are then dried and ground to form a core polymer.
  • the core polymer After the core polymer is made, it is surface crosslinked to provide superabsorbent particles having a low crosslink density within the particle core and a high crosslink density on the surface of the particle.
  • a mixture is formed from 100 parts by weight of the core polymer and about 0.001 to about 30 parts by weight of organic carbonates, polyquaternary amines or polyvalent metal compounds.
  • the core polymer is reacted with the organic carbonates, polyquaternary amines or polyvalent metal compounds to crosslink molecular chains existing on a surface of the core polymer, forming the superabsorbent polymer.
  • the core polymer is formed in solution, or in a water-in-oil emulsion containing carboxylic acid containing monomers and a crosslinking agent.
  • An effective microcellular forming amount of the carbonate blowing agent is added to the monomer solution to form the carbonated monomer solution.
  • a polymerization initiator is added to the monomer solution or the carbonated monomer solution for the purpose' of initiating the reaction between the monomers and the crosslinking agent.
  • the initiator is either added tothe monomer solution immediately before or simultaneously with addition of the blowing agent, or is added to the carbonated monomer solution immediately after the blowing agent has been added to the monomer solution.
  • the initiator is added within no more than five minutes before, or fifteen minutes after the addition of the carbonate blowing agent to the monomer solution. Simultaneous addition of both initiator and blowing agent, or addition of initiator after the addition of blowing agent is preferred.
  • the core polymer is preferably formed from a thin layer of the carbonated monomer solution, which has been deaerated (purged of oxygen).
  • the thin layer solution is preferably deaerated and protected from air before polymerization, and after in itiating polymerization by the addition of free radical catalysts or by ionizing radical forming radiation.
  • the polymerization forms an aqueous hydrogel of the crosslinked, water insoluble core polymer.
  • the polymerization is exothermic, causing the gel temperature to increase from the initial temperature of the carbonated monomer solution of about 0°C to 20°C to temperatures of about 80°C to 130°C.
  • the aqueous gel in the presence of the carbonate . blowing agent, develops a microcellular hydrogel as polymerization occurs because decomposition of the carbonate blowing agent upon heating disperses carbon dioxide throughout the hydrogel.
  • the microcellular structure of the core polymer may appear cloudy (demonstrating relatively small dispersed gas bubbles), opaque (normally representing somewhat larger gas bubbles or higher quantities of carbon dioxide), or foamy.
  • the microcellular gel volume increases range from about 1.01 to at least 10.0 times the volume of the carbonated monomer solution, primarily depending upon the concentration of the carbonate blowing agent contained in the carbonated monomer solution.
  • the microcellular gel is then masticated by chopping, grinding, or otherwise forming gel pieces have particle diameter sizes ranging from about 0.1 millimeter to about 5.0 centimeters, preferably about 10 millimeters to about 2.0 centimeters. These masticated gel pieces are then dried at temperatures ranging from about 55°C to about 210°C to form a dry superabsorbent core polymer. The core polymer is then ground to a particle size having a diameter of from about 0.05 millimeter to about 5.0 millimeters. The resultant core polymer as described in U.S.
  • the surface region of the core polymer is crosslinked using a surface crosslinking agent to obtain the superabsorbent polymer of the present invention.
  • Surface crosslinking of the core polymer improves the absorption under pressure, absorption rate, and gel strength after absorption while maintaining an acceptable absorption capacity.
  • the surface crosslinking agents for use in the present invention are organic carbonates, polyquaternary amines and polyvalent metal compound. 100 parts by weight of the core polymer formed as described above are mixed with about 0.001 to about 30 parts by weight of a surface crosslinking agent, depending upon the selected core polymer, and the surface region of the core polymer is reacted with the surface crosslinking agent. The reaction can be carried out during and/or after mixing using a conventional mixer.
  • the reaction between the core polymer and the surface crosslinking agent may occur at room temperature as when an aziridine compound is selected as the surface crosslinker.
  • Heat is preferably applied to promote the reaction although it is not required to effect the reaction in many instances.
  • the heat is preferably applied after the core polymer and the surface crosslinking agent have been mixed.
  • the temperature of the heat treatment is generally in the range of 40°C to 250°C, preferably in the range of 90°C to 250°C. At temperatures exceeding 250°C, the core polymer could be subject to thermal daterioration.
  • the mixture can be heated using conventional dryers or heating ovens.
  • the materials required to produce the superabsorbent polymers of the invention are specified below.
  • the core polymer is formed using monomers in an aqueous solution, or monomers dissolved in water and then dispersed in a water-in-oil emulsion.
  • the hydrogel-forming core polymer is normally synthesized from aqueous solutions containing acrylic acid, methacrylic acid, their water soluble salts, and mixtures thereof.
  • the monomers are preferably dissolved in an aqueous solution containing the crosslinking agent.
  • the monomer solution contains at least 20 percent by weight total monomer content, preferably about 25 to about 75 percent by weight total monomer content, and most preferably from about 30 to about 60 percent by weight total monomer content.
  • Any olefinically unsaturated carboxylic acid and carboxylic acid anhydride monomers can be used to form the core polymer of the invention.
  • Suitable monomers include acrylic acids and their anhydrides such as acrylic acid, methacrylic acid, ethacrylic acid, alpha-chloroacrylic acid, alphacyanoacrylic acid, and beta-methyl acrylic acid.
  • the term (meth)acrylic acid represents the presence of acrylic acid alone, methacrylic acid alone, any admixture of these acids, and any water soluble salt of these acids, either alone or in admixture.
  • the unsaturated carboxylic acid monomers can also include itaconic acid, citraconic acid, maleic acid, fumaric acid, and maleic anhydride.
  • olefinic unsaturated monomers can also be used, such as the sulfonic acid monomers.
  • These monomers can be chosen from, but are not limited to, vinyl sulfonic acids, allyl sulfonic acids, styrene esters including sulfoacrylic and methacrylic acid esters such as sulfoethylacrylate, sulfoethylmethacrylate, sulfopropylacrylate, and sulfopropylmethacrylate, and sulfo(meth)acrylamide materials such as acrylamido N-methylene sulfonic acid, acrylamido-N-ethylene sulfonic acid, and 2-acrylamido-2-methylpropane sulfonic acid.
  • Other olefinically unsaturated monomers such as acrylamide and methacrylamide are useful in forming copolymers which can be crosslinked to form a core polymer.
  • the monomers are preferably selected from the group consisting of acrylic acid, the water soluble salts of acrylic acid, methacrylic acid, the water soluble salts of methacrytic acid, and mixtures thereof.
  • a preferred monomer mixture consists essentially of from 20 weight percent to 40 weight percent (meth)acrylic acid and from 60 weight percent to 80 weight percent sodium (meth)acrylate.
  • the core polymer is made from free acid, partially neutralized monomers, or is partially or completely neutralized either before or after polymerization by addition of appropriate base materials, such as sodium hydroxide, ammonia, and the like. Any suitable basic salt forming cation including the alkaline metals, ammonia, ammonium salts, and amines may be used for the purpose of neutralization.
  • a degree of neutralization of the carboxylic acid monomers of at least 50 mole percent and up to about 60 to 80 mole percent.
  • the degree of neutralization can be partially accomplished by the addition of the carbonate blowing agents.
  • the carboxyl group is present in the core polymer in an amount of not less than 0.01 equivalent, based on 100 g of the core polymer.
  • the proportion of the unneutralized polyacrylic acid is preferably in the range of 1 to 50 mole percent, preferably 5 to 40 mole percent.
  • the crosslinking agents that can be used to form the monomer solution include, but are not limited to, compounds having at least two polymerizable double bonds, compounds having at least one polymerizable double bond and at least one functional group reactive with the acid containing monomer material, compounds having at least two functional groups reactive with the acid containing monomer material, and polyvalent metal compounds, which metallic cations can form ionic crosslinkages.
  • Crosslinking agents containing at least two polymerizable double bonds include di, tri or polyvinyl compounds such as divinyl benzene and divinyl toluene, di, tri or polyesters of unsaturated mono or poly carboxylic acids with polyols including di or tri acrylic acid esters of polyols such as ethylene glycol, trimethylpropane, glycerine, and polyoxyethylene glycols.
  • crosslinking agents can include alkylene bis-acrylamides such as N,N'-methylene-bis-acrylamide, carbamyl esters obtained by reacting polyisocyanates with hydroxyl group containing monomers, di, tri or poly allyl esters of polyols, di, tri or poly allyl esters of polycarboxylic acids such as diallyl phthalate and diallyl adipate, poly carboxylic acid polyols such as trimethylolpropane triacrylate, esters of unsaturated mono or poly-carboxylic acids with monoallyl esters of polyols such as the acrylic acid ester of polyethylene glycol monoallyl ether, and di or triallyl amine, and the alkylene glycol diglycidyl ethers.
  • alkylene bis-acrylamides such as N,N'-methylene-bis-acrylamide
  • carbamyl esters obtained by reacting polyisocyanates with hydroxyl group containing monomers
  • the crosslinking agent is present in an amount ranging from about 0.005 weight percent of the monomer solution to about 2.0 weight percent of the monomer solution.
  • the crosslinking agent is used in an amount ranging from about 0.10 weight percent to about 1.0 weight percent based on the weight of the monomer solution.
  • the most preferred crosslinking agents are bis-acrylamides such as N-N'-methylene bis-acrylamide, the di, tri or polyesters of unsaturated mono or poly carboxylic acid polyols such as trimethylolpropane triacrylate, the di or tri glycidyl ethers of polyols such as ethylene glycol diglycidyl ether, the multi-substituted allyl amines such as diallyl amine and triallyl amine, or mixtures thereof.
  • bis-acrylamides such as N-N'-methylene bis-acrylamide
  • the di, tri or polyesters of unsaturated mono or poly carboxylic acid polyols such as trimethylolpropane triacrylate
  • the di or tri glycidyl ethers of polyols such as ethylene glycol diglycidyl ether
  • the multi-substituted allyl amines such as diallyl amine and triallyl amine, or mixtures thereof.
  • Carbonate blowing agents are added to the monomer solution to form the carbonated monomer solution.
  • the blowing agent releases carbon dioxide when heated while dissolved or dispersed in the carbonated monomer solution.
  • the blowing agent can be any carbonate or bicarbonate containing salt or mixed salt, and may include carbon dioxide as a gas or a solid, sodium carbonate, potassium carbonate, ammonium carbonate, magnesium carbonate, or magnesium (hydroxic) carbonates, calcium carbonate, barium carbonate, bicarbonates and their hydrates, or other cations, as well as naturally occurring carbonates, such as dolomite, and mixtures thereof.
  • Preferred carbonate blowing agents are MgCO 3 , (NH 4 ) 2 CO 3 , Na 2 CO 3 , and mixtures thereof.
  • blowing agents must be added before or immediately after polymerization is initiated. The blowing agents are not effective if added after the hydrogel is formed, nor is it effective when added after chopping or drying the gelled polymer.
  • the preferred blowing agents are carbonate salts of multivalent cations such as magnesium, calcium, and zinc.
  • multivalent transition metal cations such as ferric cation
  • ferric cation can cause color staining and may be subject to reduction-oxidation reactions or hydrolysis equilibria in water. This may lead to difficulties in quality control of the final polymeric product.
  • other multi-valent cations such as nickel, barium, cadmium, and mercury would be unacceptable because of potential toxic or skin sensitizing effects.
  • the polymerization of the carbonated monomer solution is initiated with free radical catalysts which are well known in the art.
  • free radical catalysts which are well known in the art.
  • These initiators may include, but are not limited to, peroxide or persulfate catalysts, azo catalysts, the so called redox catalysts, or any combination thereof.
  • Preferred catalysts include hydrogen peroxide, sodium persulfate, organic peroxides, sodium bisulfite, peracetate catalysts, azo catalysts and mixtures thereof.
  • the surface crosslinking agents for use in the present invention are organic carbonates, polyquaternary amines and polyvalent metal compounds.
  • the surface crosslinking agents according to the present invention preferably include polyvalent metal compounds such as salts, (represented by sulfates), for example, and polyquaternary amines such as condensation products of dimethylamine and epichlorohydrin, homo and copolymers of diallyldimethyl ammonium chloride, and homo and copolymers of dimethylaminoethyl(meth)acrylate methyl chloride quaternary ammonium salts.
  • polyvalent metal compounds such as salts, (represented by sulfates), for example
  • polyquaternary amines such as condensation products of dimethylamine and epichlorohydrin, homo and copolymers of diallyldimethyl ammonium chloride, and homo and copolymers of dimethylaminoethyl(meth)acrylate methyl chloride quaternary ammonium salts.
  • the surface crosslinking agent is, ethylene carbonate.
  • the crosslinking agent is used in an amount ranging from about 0.001 to about 30 parts by weight, preferably about 0.1 to about 10 parts by weight, based upon 100 parts by weight of the core polymer.
  • Organic solvents or water can be added as the core polymer and the surface crosslinking agent are mixed to promote uniform dispersion.
  • the amount of water to be used is in the range of 0 to about 50 parts by weight, preferably up to about 40 parts by weight, more preferably up to about 20 parts by weight, based upon 100 parts by weight of the core polymer. If the amount of water exceeds 50 parts by weight, drying time is increased and the surface crosslinking agent permeates to the center of the core polymer particles, reducing the absorption capacity.
  • Organic solvents can be added to the mixture in an amount of 0 to about 50 parts by weight, preferably up to about 10 parts by weight, based upon 100 parts by weight of the core polymer. Amounts of solvent in excess of 60 parts by weight increase the required drying time of the superabsorbent.
  • the organic solvents include lower alcohols such as methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, secbutanol, and t-butanol, ketones such as acetone, methylethyl ketone and methylisobutyl ketone, ethers such as dioxane, tetrahydrofuran and diethyl ether, amides such as N,N-dimethyl formamide and N,N-diethyl formamide, and sulfoxides such as dimethyl sulfoxide.
  • lower alcohols such as methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, secbutanol, and t-butanol
  • ketones such as acetone, methylethyl ketone and methylisobutyl ketone
  • ethers such
  • Absorbent articles such as diapers, adult incontinence pads, sanitary napkins and bandages may have a core entirely composed of the superabsorbent polymer of the present invention, or can include polymer layers comprised of up to 100% of the superabsorbent polymer within the core material.
  • AUP Absorption under pressure
  • the dish is filled with 0.9 wt.% saline or synthetic urine to the top level of the filter plate and a piece of Whatman filter paper #1 is placed on top of the plate.
  • 0.9000 grams of polymer is distributed evenly over a 400 mesh screen (aperture 0,038 mm) fixed to the bottom of a plastic cylinder.
  • a teflon plunger and a weight exerting 2,1 kPa (0.3) ot 4,9 kPa (0.7 psi) is placed inside the cylinder and the entire cylinder assembly is weighed.
  • the cylinder assembly is placed on the filter plate and allowed to absorb fluid for a specified time and then reweighed.
  • the level of fluid in the dish is kept constant during absorption.
  • the absorption under pressure is calculated by dividing the difference in the complete cylinder apparatus weight before and after absorption by the dry weight of the polymer.
  • Centrifuge capacity is calculated by placing 0.2000 ⁇ 0.005 grams of polymer in a tea bag and sealing the bag. The bag is then placed in 0.9% saline or synthetic urine along with blanks (empty bags).and is allowed to absorb for a specified time. The tea bags are removed from the test liquid and centrifuged at 1500 rpm for three minutes. The weight of the tea bags and blanks is recorded. The absorptive centrifuge capacity is calculated by subtracting the weight of the blank and the dry polymer from the weight of the wet bag containing polymer, and dividing that amount by the dry polymer weight.
  • Swell rate is determined by screening 0.358 ⁇ 0.001 grams polymer to a -20/+50 mesh (aperture 0,833/0,295 mm) particle size, weighing the polymer and placing it in a 16 mm test tube. 10.0 ml of synthetic urine is added to the tube at time zero. The time required for the gel to swell to the bottom of the fluid meniscus is recorded. The swell rate is calculated by dividing the volume of fluid absorbed by the mass of the polymer used and the time required to absorb the fluid.
  • the synthetic urine tested contains the following cations and anions or elements dissolved in water: 600-700 ppm Na+, 65-75 ppm Ca 2+ , 55-65 ppm Mg 2+ , 1100-1200 ppm K + , 240-280 ppm phosphorus, 450-500 ppm sulfur, 1100-1300 ppm chloride, and 1300-1400 ppm sulfate.
  • Aqueous monomer solutions containing about 30 to 40 weight percent of a combination of acrylic acid and sodium acrylate in a ratio of about 30:70 and triallyl amine crosslinking agent in the amounts specified in Table 1 were formed.
  • the samples were polymerized without incorporation of a blowing agent.
  • the resultant gel was ground and dried, and the characteristics of the nonporous core polymer were measured using the tests described above for determining gel strength, capacity and swell rate. These results are reported as samples 1 and 3 in Table 1.
  • the nonporous core polymers of samples 1 and 3 were then surface crosslinked by reacting the polymers with from about 1 to about 3 weight percent ethylene carbonate to form the superabsorbent polymers of samples 2 and 4, respectively.
  • Aqueous monomer solutions containing about 30 to 40 weight percent of a combination of acrylic acid and sodium acrylate in a ratio of about 30:70 and triallyl amine crosslinking agent in the amounts specified in Table 2 were formed.
  • the samples were polymerized without incorporation of a blowing agent.
  • the resultant gel was ground and dried, and the characteristics of the nonporous core polymer were measured using the tests described above for determining gel strength, capacity and swell rate. These results are reported as samples 1, 3 and 5 in Table 2.
  • the nonporous core polymers of samples 1, 3 and 5 were then surface crosslinked by reacting the polymers with from about 3 weight percent glycerol to form the superabsorbent polymers of samples 2, 4 and 6, respectively.
  • Aqueous monomer solutions containing about 30 to 40 weight percent of a combination of acrylic acid and sodium acrylate in a ratio of about 30:70 and triallyl amine crosslinking agent in the amounts specified in Table 3 were formed.
  • 0.4 weight percent Na 2 CO 3 blowing agent was added to the monomer solution, forming a carbonated monomer solution.
  • the samples were polymerized and the resultant microcellular gel was ground and dried. The characteristics of the porous core polymer were measured using the tests described above for determining gel strength, capacity and swell rate. These results are reported as samples 1, 3 and 5 in Table 3.
  • the porous core polymers of samples 1, 3 and 5 were then surface crosslinked by reacting the polymers with from about 1 to about 3 weight percent glycerol to form the superabsorbent polymers of samples 2, 4 and 6, respectively.
  • the gel strength, capacity and swell rate for the samples are listed below: Sample Swell Rate (g/g sec) Gel Strength (dynes/cm 2 ) [10 -3 N/mm 2 ] Capacity (g/g) AUP @ 5 mins. (g/g) AUP @ 60 mins.
  • the swell rate, gel strength and absorption under pressure substantially improved. Although the capacity was reduced, it remained within an acceptable range.
  • incorporation of a blowing agent in the core polymer improved the swell rate of the polymer even though the swell rate, in most instances, would have declined after surface crosslinking.
  • the swell rates of the superabsorbents derived from porous core polymers were two to three times greater than those of Example 2.

Claims (24)

  1. Polymère super-absorbant qui peut être obtenu selon un procédé comprenant les étapes suivantes :
    a) préparation d'une solution contenant des monomères d'acide carboxylique ou leurs sels solubles dans l'eau et un agent de réticulation ;
    b) addition à la solution d'un agent gonflant de carbonate et d'un initiateur de polymérisation, individuellement ou en combinaison, pour former une solution de monomère carbonatée ;
    c) polymérisation de la solution monomère carbonatée à des températures dans la gamme de 0 à environ 130°C pour former un hydrogel micro-cellulaire ;
    d) hachage ou broyage de l'hydrogel micro-cellulaire en morceaux de gel avec un diamètre de particule dans la gamme d'environ 0,1 mm à environ 5,0 cm ;
    e) séchage des morceaux de gel à des températures dans la gamme d'environ 85 à environ 210°C ;
    f) moulure des morceaux de gel pour former un polymère avec une taille de particule entre environ 0,05 et environ 5,0 mm ;
    g) mélangeage de 100 parties en poids du polymère avec environ 0,001 à environ 30 parties en poids de carbonates organiques, d'amines polyquatemaires ou de composés de métals polyvalents et
    h) réaction du polymère avec les carbonates organiques, les amines polyquatemaires ou les composés de métals polyvalents pour réticuler entre elles les chaínes de molécules présentes sur la surface du polymère pour former le polymère super-absorbant.
  2. Polymère selon la revendication 1, dans lequel la solution de monomère carbonatée de l'étape b) est une solution aqueuse contenant environ 20 à 40 % en poids de monomères d'acide (méth)acrylique qui sont constitués essentiellement de 20 à 40 % en poids d'acide (méth)acrylique et de 60 à 80 % en poids de (méth)acrylate de sodium, environ 0,05 à environ 2,5 % en poids d'agent gonflant et environ 0,005 à environ 2,0 % en poids d'agent de réticulation.
  3. Polymère selon la revendication 2, dans lequel l'agent gonflant de l'étape b) est un sel contenant un carbonate, un sel contenant un bicarbonate ou un anhydride carbonique gazeux ou solide.
  4. Polymère selon la revendication 3, dans lequel l'agent gonflant est choisi du groupe comprenant CO2, Na2CO3, K2CO3, (NH4)2CO3, MgCO3, (MgCO3)4 · Mg(OH)2 · 5H2O, CaCO3, ZnCO3 et leurs mélanges.
  5. Polymère selon l'une des revendications 1 à 4, dans lequel l'agent de réticulation de l'étape a) comprend au moins deux liaisons doubles polymérisables ou au moins une liaison double polymérisable et au moins un groupe fonctionnel qui peut réagir avec les monomères d'acide ou leurs sels solubles dans l'eau, ou au moins deux groupes fonctionnels qui peuvent réagir avec les monomères d'acide ou leurs sels solubles dans l'eau, ou est un composé de métal polyvalent.
  6. Polymère selon la revendication 5, dans lequel l'agent de réticulation est un bisacrylamide, un diester, un triester ou un polyester d'un polyol d'acide mono- ou polycarboxylique non-saturé, un di- ou triglycidyléther d'un polyol, un allylamine multi-substitué ou un de leurs mélanges.
  7. Polymère selon l'une des revendications 1 à 6, dans lequel l'initiateur de polymérisation de l'étape b) est choisi du groupe comprenant le peroxyde d'hydrogène, le persulfate de sodium, des catalyseurs azoïques, des peroxydes organiques, le bisulfite de sodium, des catalyseurs de peracetate et leurs mélanges.
  8. Polymère selon l'une des revendications 1 à 7, dans lequel les monomères d'acide carboxylique de l'étape a) sont choisis du groupe comprenant l'acide acrylique, l'acide méthacrylique, l'acrylamide, le méthacrylamide, l'acide éthacrylique, l'acide α-chloroacrylique, l'acide α-cyanoacrylique, l'acide β-méthacrylique, l'acide itaconique, l'acide citraconique, l'acide maléique, l'acide fumarique, l'anhydride d'acide maléique, les acides vinylsulfoniques, les acides allylsulfoniques, le sulfoéthylacrylate, le sulfoéthylméthacrylate, le sulfopropylacrylate, le sulfopropylméthacrylate, l'acide sulfonique d'acrylamido-N-méthylène, l'acide sulfonique d'acrylamido-N-éthylène, l'acide sulfonique de 2-acrylamido-2-methylpropane, l'acrylamide, le méthacrylamide et leurs mélanges.
  9. Polymère selon l'une des revendications 1 à 8, dans lequel le procédé comprend en outre l'étape i) séchage du polymère super-absorbant par application de chaleur.
  10. Polymère selon l'une des revendications 1 à 9, dans lequel l'agent gonflant de carbonate n'est ajouté à la solution de monomère pas plus que 5 minutes avant l'addition de l'initiateur.
  11. Polymère selon l'une des revendications 1 à 10, dans lequel l'initiateur n'est ajouté à la solution de monomère pas plus que 15 minutes après l'addition de l'agent gonflant de carbonate.
  12. Procédé pour la réalisation d'un polymère super-absorbant ayant une absorption sous pression et un taux d'absorption amélioré lors de l'absorption de fluides corporels aqueux, le procédé comprenant les étapes suivantes :
    a) préparation d'une solution contenant des monomères d'acide carboxylique ou leurs sels solubles dans l'eau et un agent de réticulation ;
    b) addition à la solution d'un agent gonflant de carbonate et d'un initiateur de polymérisation, individuellement ou en combinaison, pour former une solution de monomère carbonatée ;
    c) polymérisation de la solution monomère carbonatée à des températures dans la gamme de 0 à environ 130°C pour former un hydrogel micro-cellulaire ;
    d) hachage ou broyage de l'hydrogel micro-cellulaire en morceaux de gel avec un diamètre de particule dans la gamme d'environ 0,1 mm à environ 5,0 cm ;
    e) séchage des morceaux de gel à des températures dans la gamme d'environ 85 à environ 210°C ;
    f) moulure des morceaux de gel pour former un polymère avec une taille de particule entre environ 0,05 et environ 5,0 mm ;
    g) mélangeage de 100 parties en poids du polymère avec environ 0,001 à environ 30 parties en poids de carbonates organiques, d'amines polyquaternaires ou de composés de métals polyvalents et
    h) réaction du polymère avec les carbonates organiques, les amines polyquaternaires ou les composés de métals polyvalents pour réticuler entre elles les chaínes de molécules présentes sur la surface du polymère pour former le polymère super-absorbant.
  13. Procédé selon la revendication 12, dans lequel la solution de monomère carbonatée de l'étape b) est une solution aqueuse contenant environ 20 à 40 % en poids de monomères d'acide (méth)acrylique qui sont constitués essentiellement de 20 à 40 % en poids d'acide (méth)acrylique et de 60 à 80 % en poids de (méth)acrylate de sodium, environ 0,05 à environ 2,5 % en poids d'agent gonflant et environ 0,005 à environ 2,0 % en poids d'agent de réticulation.
  14. Procédé selon la revendication 13, dans lequel l'agent gonflant de l'étape b) est un sel contenant un carbonate, un sel contenant un bicarbonate ou un anhydride carbonique gazeux ou solide.
  15. Procédé selon la revendication 14, dans lequel l'agent gonflant est choisi du groupe comprenant CO2, Na2CO3, K2CO3, (NH4)2CO3, MgCO3, (MgCO3)4 · Mg(OH)2 · 5H2O, CaCO3, ZnCO3 et leurs mélanges.
  16. Procédé selon l'une des revendications 12 à 15, dans lequel l'agent de réticulation de l'étape a) comprend au moins deux liaisons doubles polymérisables ou au moins une liaison double polymérisable et au moins un groupe fonctionnel qui peut réagir avec les monomères d'acide ou leurs sels solubles dans l'eau, ou au moins deux groupes fonctionnels qui peuvent réagir avec les monomères d'acide ou leurs sels solubles dans l'eau, ou est un composé de métal polyvalent.
  17. Procédé selon la revendication 16, dans lequel l'agent de réticulation est un bisacrylamide, un diester, un triester ou un polyester d'un polyol d'acide mono- ou polycarboxylique non-saturé, un di- ou triglycidyléther d'un polyol, un allylamine multi-substitué ou un de leurs mélanges.
  18. Procédé selon l'une des revendications 12 à 17, dans lequel l'initiateur de polymérisation de l'étape b) est choisi du groupe comprenant le peroxyde d'hydrogène, le persulfate de sodium, des catalyseurs azoïques, des peroxydes organiques, le bisulfite de sodium, des catalyseurs de peracetate et leurs mélanges.
  19. Procédé selon l'une des revendications 12 à 18, dans lequel les monomères d'acide carboxylique de l'étape a) sont choisis du groupe comprenant l'acide acrylique, l'acide méthacrylique, l'acrylamide, le méthacrylamide, l'acide éthacrylique, l'acide α-chloroacrylique, l'acide α-cyanoacrylique, l'acide β-méthacrylique, l'acide itaconique, l'acide citraconique, l'acide maléique, l'acide fumarique, l'anhydride d'acide maléique, les acides vinylsulfoniques, les acides allylsulfoniques, le sulfoéthylacrylate, le sulfoéthylméthacrylate, le sulfopropylacrylate, le sulfopropylméthacrylate, l'acide sulfonique d'acrylamido-N-méthylène, l'acide sulfonique d'acrylamido-N-éthylène, l'acide sulfonique de 2-acrylamido-2-methylpropane, l'acrylamide, le méthacrylamide et leurs mélanges.
  20. Procédé selon l'une des revendications 12 à 19 qui comprend en outre l'étape i) séchage du polymère super-absorbant par application de chaleur.
  21. Procédé selon l'une des revendications 12 à 20, dans laquelle l'agent gonflant n'est ajouté à la solution de monomère pas plus que 5 minutes avant l'addition de l'initiateur.
  22. Procédé selon l'une des revendications 12 à 21, dans lequel l'initiateur n'est ajouté à la solution de monomère pas plus que 15 minutes après l'addition de l'agent gonflant de carbonate.
  23. Procédé pour l'amélioration de l'absorption sous pression d'un polymère super-absorbant comprenant les étapes suivantes :
    a) préparation d'une solution contenant des monomères d'acide carboxylique ou leurs sels solubles dans l'eau et un agent de réticulation ;
    b) addition à la solution d'un agent gonflant de carbonate et d'un initiateur de polymérisation, individuellement ou en combinaison, pour former une solution de monomère carbonatée ;
    c) polymérisation de la solution monomère carbonatée à des températures dans la gamme de 0 à environ130°C pour former un hydrogel micro-cellulaire ;
    d) hachage ou broyage de l'hydrogel micro-cellulaire en morceaux de gel avec un diamètre de particule dans la gamme d'environ 0,1 mm à environ 5,0 cm ;
    e) séchage des morceaux de gel à des températures dans la gamme d'environ 85 à environ 210°C ;
    f) moulure des morceaux de gel pour former un polymère avec une taille de particule entre environ 0,05 et environ 5,0 mm ;
    g) mélangeage de 100 parties en poids du polymère avec environ 0,001 à environ 30 parties en poids de carbonates organiques, d'amines polyquaternaires ou de composés de métals polyvalents et
    h) réaction du polymère avec les carbonates organiques, les amines polyquaternaires ou les composés de métals polyvalents pour réticuler entre elles les chaínes de molécules présentes sur la surface du polymère pour former le polymère super-absorbant.
    i) faire agir des liquides corporels aqueux sur le polymère super-absorbant en exerçant une pression sur le polymère super-absorbant.
  24. Procédé selon la revendication 23, dans lequel le polymère super-absorbant est contenu dans une lange, une serviette hygiénique pour incontinence, une serviette hygiénique ou un tampon hygiénique quand une pression est exercée sur le polymère super-absorbant.
EP94114621A 1993-09-17 1994-09-16 Polymère superabsorbant de pouvoir absorbant perfectionné et d'absorption sous pression améliorée Expired - Lifetime EP0644207B2 (fr)

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US08/123,561 US5314420A (en) 1993-09-17 1993-09-17 Superabsorbent polymer having improved absorption rate and absorption under pressure

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US5399591A (en) 1995-03-21
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DE69401325T3 (de) 2004-12-30
US5314420A (en) 1994-05-24
JPH07185331A (ja) 1995-07-25
EP0644207A1 (fr) 1995-03-22
DE69401325D1 (de) 1997-02-13
DE69401325T2 (de) 1997-08-14

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